Magna Seating Pallet Racking Case Study

Pallet Racking Case Study

Magna Seating Detroit

Customer Details

Customer: Magna Seating

Location: Detroit, MI

Product: Interlake Mecalux Pallet Racking, Unex Flow Racking

Company Overview:

Magna Seating is a global automotive supplier specializing in the design, engineering, testing, and manufacturing of complete seat systems and seating components for original equipment manufacturers (OEMs). As a division of Magna International, the company operates within one of the world’s largest automotive supply organizations.

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Challenge

Magna Seating required expanded storage capacity within its warehouse to support rising production volumes and increasingly complex material flow requirements. As operations scaled, the existing layout lacked the storage density and organization necessary to efficiently manage higher inventory levels while maintaining just-in-time delivery to production lines. To address these challenges, a combined system of structural pallet racking and UNEX Manufacturing flow racking was implemented. The pallet racking system maximized vertical cube utilization for bulk and reserve inventory, while the UNEX gravity flow racking introduced first-in, first-out (FIFO) inventory control for high-velocity components and line-side replenishment. This integrated approach improved inventory visibility, accelerated picking efficiency, and reduced unnecessary material handling. Floor congestion was minimized, storage lanes were clearly defined, and overall warehouse organization improved. The enhanced storage infrastructure not only strengthened safety compliance but also positioned Magna Seating to scale production capacity while maintaining operational precision and supply chain reliability.

The Safety Source Pallet Racking Solution

The Safety Source, specialists in designing and installing customized safety and storage systems, partnered with Magna Seating to address evolving warehouse capacity and organization challenges. The engagement focused on delivering a scalable pallet racking solution aligned with Magna Seating’s production-driven material flow requirements.

Initial Consultation and Design:

The Safety Source began with a comprehensive on-site evaluation of Magna Seating’s warehouse layout, SKU velocity, pallet weights, and production material requirements. Because seating manufacturing environments require consistent part availability and controlled inventory flow, the solution was designed to support both bulk storage and high-rotation components.
Working closely with Magna Seating’s operations team, we developed a hybrid storage strategy that included:
- Structural pallet racking for reserve and bulk pallet storage
- UNEX Manufacturing flow racking systems for high-turn components and FIFO inventory control
- Optimized aisle spacing for forklift efficiency
- Engineered load calculations for varying pallet and carton weights
- Future scalability built into the rack layout
The integration of UNEX flow racking allowed Magna Seating to implement first-in, first-out (FIFO) inventory management, improving material rotation and reducing handling time for production-critical parts.
Custom Installation:

The Safety Source executed the installation of the pallet racking system using high-quality structural components from Interlake Mecalux, combined with UNEX gravity flow rack modules for carton-level picking and line-side replenishment.
The installation was phased to minimize disruption to ongoing operations. Our certified installers ensured:
- Proper anchoring and leveling of pallet rack frames
- Accurate beam placement aligned with engineered load ratings
- Seamless integration of UNEX flow lanes for smooth carton travel
- Correct pitch and brake configuration on flow rails for controlled product movement
The result was a fully integrated storage system that improved vertical cube utilization while simultaneously enhancing picking speed and workflow efficiency for production support.
Safety and Compliance:

Safety and structural compliance were prioritized throughout the project. All racking components were installed in accordance with manufacturer specifications and industry standards for warehouse storage systems.
In addition, The Safety Source provided operational guidance to Magna Seating’s team on:
- Load capacity adherence and rack labeling
- Safe forklift interaction with pallet rack systems
- Routine inspection and maintenance procedures
- Proper use of flow racking to maintain consistent FIFO sequencing
By combining structural pallet racking with UNEX flow systems, Magna Seating gained increased storage density, improved inventory control, and more efficient material movement—positioning the facility for sustained production growth while maintaining a safe, organized warehouse environment.

The Result

The installation of a custom-engineered storage system by The Safety Source significantly enhanced Magna Seating’s warehouse performance by integrating structural pallet racking with high-density flow systems to better support production-driven material movement.

Increased Storage Capacity and Space Utilization:

The implementation of structural pallet racking from Interlake Mecalux, combined with gravity-fed flow systems from UNEX Manufacturing, substantially increased Magna Seating’s storage density.
Bulk and reserve inventory was consolidated vertically using pallet racking, maximizing cubic space within the existing footprint. Simultaneously, UNEX flow racking was installed for high-velocity components, enabling organized carton storage with controlled FIFO rotation.
This dual-system approach reduced floor congestion, improved slotting strategy, and created clearly defined storage zones that aligned with production demand. The result was a more structured, high-efficiency warehouse environment capable of supporting growing output volumes.
Enhanced Workflow Efficiency:

With pallet inventory strategically positioned and flow lanes feeding high-turn parts in sequence, material handling efficiency improved across the facility. Operators gained faster access to components, reducing travel time and minimizing staging bottlenecks.
The UNEX flow racking system streamlined picking operations by allowing gravity-fed cartons to move forward automatically, improving ergonomics and ensuring consistent part rotation.
Together, these improvements reduced downtime, accelerated replenishment cycles, and strengthened Magna Seating’s ability to maintain just-in-time delivery to production lines.
Scalable and Future-Ready Solution:

Beyond immediate operational gains, the integrated pallet and flow racking solution positioned Magna Seating for long-term scalability. The modular design of both the pallet rack structure and UNEX flow lanes allows for straightforward expansion or reconfiguration as production requirements evolve.
This future-ready storage infrastructure ensures Magna Seating can continue increasing throughput, managing higher SKU counts, and adapting to shifting production schedules without major facility disruption—supporting sustained operational efficiency and supply chain reliability.

"As our production volumes increased, we needed a storage solution that would support line-side efficiency without expanding our footprint. The combination of pallet racking and flow systems gave us better inventory control and significantly improved material flow to our production lines. The installation was well-coordinated, completed on schedule, and designed with future growth in mind. It’s made a measurable difference in how we manage space, safety, and overall warehouse performance."

-Production Manager, Magna Seating

Our Process

- Step 1 -

Discovery

The Safety Source will work with you to figure out the best solution for your pain points.

- Step 2 -

Design

Based on your requirements, the Safety Source will design a pallet racking layout that will fit your needs.

- Step 3 -

Installation

Our pallet racking experts will install the pallet racking according to the agreed upon design specifications.

Success Stories

The team at The Safety Source sat down and looked at our current space and provided an out of the box solution - a two story mezzanine with a inplant office installed on the 2nd floor. This solution was not only cost effective it was designed and installed on time and on budget. Thanks for being a vendor we can rely on.

Facility Manager

Magna Seating Detroit

We have been contracting The Safety Source to manage our MRO supplies with their state of the art vending software we have seen on average $6,000 per month savings! They also perform pallet racking repairs and installation. Guard rails, dock safety and LED lighting retrofits. Their team has always accommodated our busy production schedule and provided the best value.

C&I Manager

Detroit Manufacturing Systems